Variable denier yarn and suture

Abstract

A textile yarn includes a first segment and a second segment. The first segment includes a plurality of first strands and has a substantially constant first denier. The second segment includes a plurality of second strands integrated together and has a substantially constant second denier. There are more second strands in the second segment than first strands in the first segment such that the second denier is greater than the first denier. A first portion of the plurality of second strands is made from a first plurality of yarn elements that extend through the first and second segments. A second portion of the plurality of second strands is made from a second plurality of yarn elements present in the second segment and not the first segment. The yarn elements in the second plurality of yarn elements terminate in a transition zone between the first segment and the second segment.

What is claimed is: 
     
       1. A suture, comprising:
 a first segment of suture comprising a plurality of first strands, the first segment having a substantially constant first denier; and 
 a second segment of suture comprising a plurality of second strands, the second segment having a substantially constant second denier; 
 wherein the first and second segments are aligned along a longitudinal axis of the suture; 
 wherein there are more second strands in the second segment than first strands in the first segment such that the second denier is greater than the first denier; 
 wherein a first portion of the plurality of second strands is made from a first plurality of yarn elements that extend through the first segment and the second segment, and wherein a second portion of the plurality of second strands is made from a second plurality of yarn elements that are present in the second segment and not the first segment, the first portion integrated around the second portion; and 
 wherein ends of the second plurality of yarn elements are positioned along an axis that is oriented substantially transverse to the longitudinal axis. 
 
     
     
       2. The suture of  claim 1 , wherein the first portion of the plurality of second strands are braided, knitted, or woven together. 
     
     
       3. The suture of  claim 2 , wherein the plurality of first strands are braided, woven, or knitted together in a continuous element with the first portion of the plurality of second strands. 
     
     
       4. The suture of  claim 1 , wherein ends of the strands in the second plurality of yarn elements are loose in a transition zone between the first segment and the second segment. 
     
     
       5. The suture of  claim 1 , wherein the second denier is at least twice as large as the first denier. 
     
     
       6. A method of suturing, comprising:
 threading a first segment of a suture through an opening of a surgical instrument, wherein the first segment comprises a plurality of first strands, the first segment having a substantially constant first denier; and 
 pulling the suture through tissue to place a second segment of the suture against soft tissue, wherein the second segment comprises a plurality of second strands, the second segment having a substantially constant second denier; 
 wherein the first and second segments are aligned along a longitudinal axis of the suture; 
 wherein there are more second strands in the second segment than first strands in the first segment such that the second denier is greater than the first denier; and 
 wherein a first portion of the plurality of second strands is made from a first plurality of yarn elements that extend through the first segment and the second segment, and wherein a second portion of the plurality of second strands is made from a second plurality of yarn elements that are present in the second segment and not the first segment, the first portion integrated around the second portion wherein ends of the second plurality of yarn elements are positioned along an axis that is oriented substantially transverse to the longitudinal axis. 
 
     
     
       7. The method of  claim 6 , further comprising wrapping the first segment around a traction loop before threading the suture. 
     
     
       8. The suture of  claim 1 , wherein the first strands and the second portion of the plurality of second strands form the radially inner-most elements of the textile yarn. 
     
     
       9. The suture of  claim 1 , wherein the first portion of the plurality of second strands form a tubular overbraid around the second portion of the plurality of second strands. 
     
     
       10. The suture of  claim 1 , further comprising at least one third yarn element, the third yarn element extending through the first and second segment, the first portion integrated around the third yarn element. 
     
     
       11. The suture of  claim 10 , wherein there are a plurality of third yarn elements, and wherein at least some of the plurality of third yarn elements are integrated together within the second segment and not within the first segment. 
     
     
       12. The method of  claim 6 , wherein threading the first segment of a suture through an opening comprises looping the first segment through the opening such that the first segment folds upon itself. 
     
     
       13. The method of  claim 12 , wherein the folded first segment, when placed or pulled with a traction loop through a small opening, has an equivalent or smaller diameter than the second segment. 
     
     
       14. A method of manufacturing a suture, comprising:
 braiding a plurality of strands together into a tubular braid; 
 introducing a constant denier segment into a radial center of the tubular braid such that a textile yarn having a first segment and a second segment is formed, the second segment having a greater denier than the first segment; 
 introducing a plurality of additional constant denier segments into the radial center of the tubular braid such that a plurality of first segments and a plurality of second segments are formed, the first and second segments arranged in an alternating pattern along the length of the textile yarn; and 
 cutting the textile yarn such that a plurality of sutures having a first segment and a second segment are formed. 
 
     
     
       15. The method of  claim 14 , wherein the braiding and introducing steps are continuous and uninterrupted.